Pneumatic device for a vehicle seat with one or more tubes laminated to a carrier and method of making the same

Abstract

A pneumatic device for an occupant support device that includes a carrier; one or more air cells attached to the carrier; one or more tubes connected to the one or more air cells; the one or more tubes are laminated to the carrier material.

Description

PNEUMATIC DEVICE FOR A VEHICLE SEAT WITH ONE OR MORE TUBESLAMINATED TO A CARRIER AND METHOD OF MAKING THE SAMECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US 63 / 675,314 filed on July 25, 2024 and to US 63 / 770,092 filed on March 11, 2025, both of which are incorporated by reference herein in their entireties for all purposes.FIELD

[0002] These teachings relate to a pneumatic device for a vehicle seat and to a method of making the same.BACKGROUND

[0003] Some vehicle seats include one or more devices for improving occupant comfort. For example, some vehicle seats include one or more pneumatic devices to provide a support, massage, and / or lumbar function to an occupant of the vehicle seat. While these devices are generally enjoyed by consumers, improvements in these devices, including making or assembling these devices, may be desired.

[0004] For example, a pneumatic device typically includes one or more air cells provided on a carrier and attached to the seating portion and / or backrest portion of the vehicle seat. The one or more air cells are fluidly connected to one or more pumps, valves, and / or fluid sources via one or more tubes. The one or more air cells are inflated and deflated to provide support, massage, and / or lumbar function(s) to an occupant of the vehicle seat.

[0005] Typically, during manufacturing and / or assembly of the pneumatic devices and / or the vehicle seat, the one or more tubes connecting the one or more air cells to the one or more pumps, valves, and / or fluid sources are routed or weaved through or under one or more loops, holes, straps, or channels defined in, or attached to, the carrier or vehicle seat. Due at least in part because the tubes, carrier, loops, holes, straps, and / or channels are flexible and the loops, holes, straps, and / or channels are small, routing or weaving the tubes into, under, or through the loops, holes, straps, and / or channels can be time and labor intensive. Accordingly, improvement in the art may be desired.SUMMARY

[0006] These teachings provide a pneumatic device and a method of making or assembling a pneumatic device. The pneumatic device includes a carrier; one or more air cells attached to the carrier; one or more tubes connected to the one or more air cells; the one or more tubes are laminated or welded to the carrier material or laminated or welded between two carriers.

[0007] According to the advantages that can be gleaned from these teachings, a person having skill in the art will appreciate that laminating or otherwise attaching the one or more tubes to a carrier or between two carriers is much faster, efficient, and less prone to quality issues vs manually weaving .individual, tubes .into, or .through . one or. more loops, holes, straps, or channels defined in or attached to the carrier or vehicle seat. Moreover, attaching the one or more tubes via a laminating or welding process may better secure the one or more tubes to or between the carrier(s), which may help reduce chances of the one or more tubes moving, shift, or otherwise disconnecting during repeated use and when an occupant shifts their weight in the vehicle seat.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a side view of a vehicle and a vehicle seat.

[0009] FIG. 2 is a front view of a cushion of a vehicle seat that includes a comfort device.

[0010] FIG. 3 is a front view of tubes or hoses attached to a carrier of a comfort device.

[0011] FIG. 4A illustrates a step of the method disclosed herein, where a tube is being provided or inserted into a channel of a fixture.

[0012] FIG. 4B illustrates a step of the method disclosed herein, where a tube is provided or inserted into a channel of a fixture.

[0013] FIG. 4C illustrates a step of the method disclosed herein, where a tube located in a channel of a fixture is covered with a carrier and together inserted into a laminating machine or press.

[0014] FIG. 4D illustrates a step of the method disclosed herein, where the tube is laminated to the carrier.

[0015] FIG. 4E illustrates a step of the method disclosed herein, where a second carrier is laminated or attached to the tube and / or the carrier.

[0016] FIG. 4F is a cross section of a tube between two carriers located in a fixture.

[0017] FIG. 4G is a cross section of a tube between two carriers.

[0018] FIG. 5A illustrates a step of the method disclosed herein, where a tube is provided or inserted into a channel of a fixture and then subjected to a thermoforming process.

[0019] FIG. 5B is a perspective view of a tube that has been thermoformed according to a method step disclosed herein.

[0020] FIG. 5C is a front view of a thermoformed tube attached to a carrier.

[0021] FIG. 6A is a top view of a tube on a fixture that is routed between one or more pins.

[0022] FIG. 6B is a cross-sectional view of a tube on a carrier with a second carrier over the tube.

[0023] FIG. 7 is a perspective view of a tool for attaching one or more retaining straps to a carrier.

[0024] FIG. 8 is a perspective view of a tool attaching one or more retaining straps to a carrier with a tube between the retaining strap and the carrier.

[0025] FIG. 9 is a top view of retaining straps securing tubes to a carrier.DETAILED DESCRIPTION

[0026] FIG. 1 illustrates a vehicle 10. The vehicle 10 comprises one or more vehicle seats 12. The vehicle seat 12 comprises a seating portion 14 and a backrest portion 16. The seating portion 14 and / or the backrest portion 16 include a cushion 18. The cushion 18 may be a single cushion for both portions 14, 16, or the cushion 18 may be one or more cushion sections for each portion 14, 16.

[0027] The vehicle seat 12, the seating portion 14, and / or the backrest portion 16 may include one or more comfort devices 100. In the illustrated examples herein, the comfort device is a pneumatic device 100. The pneumatic device 100 may be configured to provide support, massage, and / or lumbar functions to an occupant of the vehicle seat 12.

[0028] FIG. 2 illustrates a cushion 18 and a comfort device 100. While the cushion 18 is illustrated as being configured for the backrest portion of a vehicle seat, the features of the cushion 18 may also or instead be used without limitation for the bottom or seating portion of the vehicle seat. Therefore, the description of the cushion herein is not limited to only the backrest portion unless expressly indicated. Furthermore, while the comfort device 100 is illustrated as being in the front seat, the comfort device may be in any of the back or rear seats. In otherwords, the vehicle seat may be a front seat (driver or passenger) or a back seat (located behind the front seat(s) in vehicle position).

[0029] Moreover, while the disclosure herein refers to a vehicle seat comprising one or more comfort devices 100, it is within the scope of this disclosure and understood that the teachings herein can be applied to non-vehicular seat applications, such as chairs, seats, and / or couches found in home, office, medical, and / or public settings. For example, the teachings herein can be applied to home chairs, mattresses, and / or furniture like recliners and couches, office chairs or furniture, medical seats and / or cushions, etc. The teachings herein can also be extended to other vehicular applications, such as airplanes, boats, trains, etc. Therefore, the vehicle seat, seat, etc. may be referred to generally as an occupant support device without limitation and can be found in at least any of the one or more of any of the exemplary applications disclosed herein.

[0030] A comfort device 100 may be installed at, on, within, or below the cushion 18. For example, a comfort device 100 may be placed or attached to the A-surface of the cushion 18. In some configurations, the comfort device 100 may instead or may additionally be placed or attached to the back or B-side of the cushion 18 and / or within a thickness of the cushion 18 (between the A- and B-sides of the cushion 18). The A-side of the cushion may be the side of the cushion that an occupant sits on or rests against. The B-side of the cushion may be the side of the cushion that is positioned against the seat frame.

[0031] The comfort device 100 may be configured to provide or increase occupant comfort in the vehicle seat. The comfort device 100 may be a pneumatic device configured to provide supporting, lumbar, and / or massaging functions to an occupant of the vehicle seat. The pneumatic device 100 may be of the type disclosed in, or may include one or more components illustrated and / or disclosed in, U.S. Patent Publication No. US2012 / 0313420, US 10,906,442 B2, and / or US2013 / 0127226, all of which is expressly incorporated by reference herein for all purposes.

[0032] The pneumatic device 100 generally comprises one or more air cells, reservoirs, or bladders 102 that are connected to one or more pumps, valves, and / or fluid sources via one or more tubes or conduits 104.

[0033] During use, a fluid is supplied to the one or more air cells 102 from the one or more pumps, valves, and / or fluid sources via or through one or more tubes or conduits 104 to inflate and expand the one or more air cells. The fluid is then evacuated from the one or more air cells102 to deflate and contract the one or more air cells. This inflation and deflation is configured to provide the support, massage, and / or lumbar function to an occupant of the vehicle seat. The fluid may be air or another gas.

[0034] Referring now to FIG. 3, the one or more tubes or conduits 104 can be attached or secured to the carrier 106 via one or more straps 108. The one or more straps 108 can be welded to the carrier 108 using one or more of the methods disclosed herein, including those illustrated and described in FIG. 7, 8, and 9.

[0035] In some configurations, the carrier 106 may be omitted and the one or more tubes or conduits 104 can be attached or secured directly to a cushion 18 of the seat via one or more straps 108, that can be welded to the cushion 18 using one or more of the methods disclosed herein, including those illustrated and described in FIG. 7, 8, and 9.

[0036] FIGs. 4A-4G illustrate method and / or assembly steps of making or assembling the pneumatic device 100 or at least certain parts or components of the pneumatic device 100.

[0037] In method step 202, a fixture 150 may be provided that includes one or more predefined channels 152 (See FIG. 4A). The one or more channels may have a depth, width, or size that is generally the size of the one or more tubes 104 or slightly larger than a cross section or thickness or tube size of the tube 104. The channels 152 may be one or more grooves, channels, bores, notches, absence of material, thinned out regions, depressions, or recessed regions in a top surface or face of the fixture 150. Fixture 150 may have a substantially flat and elevated surface surrounding the channels 152. Fixture 150 may be a plate that is made of a suitable material that can withstand the application of pressure and / or heat.

[0038] In method step 204, the one or more tubes 104 may be deposited, provided, inserted, or otherwise arranged at or into the one or more predefined channels 152 on the fixture 150 (FIGs. 4A-4B). The one or more tubes 104 are generally flexible so they can be easily routed and placed or arranged into the channels or grooves 152. The one or more tubes may be manually inserted into the one or more channels 152 or may be inserted into the one or more channels 152 via an automated process such as with a robot or machine.

[0039] In some configurations, the fixture 150 may be placed at the end of a tube forming line or extruder, and the one or more tubes 104 can be extruded directly or indirectly into the one or more channels 152 for further processing or assembly according to the teachings herein. This may be advantageous in that the tube 104 is still slightly warm from the forming process and caneasily be bent and routed into the channels. In other configurations, the one or more tubes 104 can be pre-heated or warmed before being inserted into the one or more channels 152 to allow the tubes to better conform to the path of the channel 152. In some configurations, the fixture and / or the channels 152 may be warm or have a raised temperature to allow the tube 104 to better confirm to the geometry of the channel 152, which can have one or a plurality of turns, bends, and winding path.

[0040] In some configurations, a vacuum or negative air pressure source 156 may be used with the fixture 150. Vacuum or negative air pressure generated by the source 156 may be applied to the one or more tubes 104, the fixture 150, and / or the one or more channels 152 to help retain the one or more tubes 104 in the one or more channels 152. This may be advantageous because depending on the pattern or routing of the one or more channels 152, the size difference between the channel 152 and tube 104, and / or the flexibility (or lack thereof) of the one or more tubes 104, the one or more tubes 104 may have a tendency to pop out of the one or more channels 152, which may make subsequent method steps difficult and / or lead to quality issues.

[0041] In method step 206, a carrier 106 may be applied or provided over or on top of the one or more tubes 104 in the channels 152 of the fixture 150. The carrier 106 may be a single sheet of cut material, or the carrier 106 may be provided on a roll that is unrolled onto the fixture and over the channels and tubes positioned therein. In other configurations, such as if the carrier 106 is omitted, a cushion (e g., cushion 18, Fig. 2) may be placed over or on top of the one or more tubes 104 in the channels 152 of the fixture 150.

[0042] The fixture 150, tubes 104, and carrier 106 (and / or cushion 18) may already be in an assembly machine 154 or may be subsequently moved or transferred to an assembly machine 154. The assembly machine may be a laminating machine or press 154 or other tool for applying heat and / or pressure. (FIG. 4C). The machine or press may be configured to apply heat and / or pressure to the carrier and tubes to create a bond or thermal bond between the carrier (or cushion) and tubes. An adhesive or other layer may be provided between the tubes and carrier to help facilitate the bond therebetween. Additionally or alternatively, a layer may be provided on or around the tubes and carrier that may be melted to adhered to the tubes and carrier (or cushion) to create the connection or bond therebetween. The connection or bond between the tubes and carrier may be a local connection (e.g., in one or more areas of the tubes and carrier).The connection or bond between the tubes and carrier may be all over the assembly (e g., the entire carrier sheet and tubes) so that all parts of the tubes and carrier are substantially covered, except for perhaps end regions of the tubes where they are connected to the one or more air cells or pumps, valves, fluid supplies, etc.

[0043] In method step 208, the carrier 106 (or cushion) and the tubes 104 laminated thereon may be removed from the machine or press 154. The tubes 104 are therefore attached to the carrier 106 and / or the carrier 106 is attached to the tubes 104. The laminating process may take place in the laminating machine or press. Heat and pressure may be used to form a bond between the carrier 106 and the one or more tubes 104. A thin layer of material may be applied over the one or more tubes 104 and the carrier 106 to attach the components together. (FIGs. 4C-4D)

[0044] One or more subsequent steps can take place where one or more air cells are attached to the one or more tubes 104 and / or carrier (or cushion); the one or more tubes 104 can be connected to one or more pumps, valves, and / or fluid sources; the carrier 106 and the tubes 104 laminated thereon may be installed in a vehicle seat; etc. Additionally or alternatively, one or more air cells or one or more layers of the air cells can be attached to the tubes, carrier, or laminating layer before, during, or after the laminating step.

[0045] As can be appreciated, by attaching the tubes 104 to the carrier 106, one or more steps of attaching the tubes 104 to the carrier 106 can be eliminated (i.e., no need to manually pass or route the tubes under or through one or more loops, holes, straps, or channels etc.

[0046] Referring now to Fig. 4E, in an additional method step 210, which may be optional, a second carrier 110 (or the cushion) may be provided or applied over the one or more tubes 104 and carrier 106. This may sandwich the one or more tubes between the two carriers 106, 110 (or between one of the carriers and the cushion). The second carrier 110 may be the same material and composition as the first carrier or may be made of a different material, such a polymer, plastic, polyurethane material. The first carrier and / or the second carrier may be part of a heater pad or layer, a ventilation device or bag, a trim layer of a vehicle seat, or any combination thereof. Heat and pressure may be used to form a bond between the carriers 106, 110 and the one or more tubes 104 to sandwich the one or more tubes 104 between the carriers 106, 110. Additionally or alternatively, other fasteners may be used to attach the second carrier to the tubes and / or first carrier, such as welding, sewing, tape, double sided tape, vibration welding, RFwelding, pinning, etc. A thin layer of material may be applied over the one or more tubes 104 and the carrier 106 to attach the components together. (FIG. 4E)

[0047] Additionally or alternatively, one or more fasteners may be used to at least temporarily secure or attach the one or more tubes to the carrier before the laminating or attachment process takes place to ensure the one or more tubes or carriers do not move or become repositioned before or during the attachment step. These additional fasteners may include any suitable fastener such as welding, sewing, tape, double sided tape, vibration welding, pinning, RF welding, etc.

[0048] Referring back to FIG. 4A, in some configurations, a carrier material 106 may first be provided or laid on the surface of the fixture 150 and cover one or more of the grooves 152. One or more tubes 104 may then be positioned on the carrier material 106 and in the one or more grooves 152. Negative air pressure or vacuum from source 156 may be applied to the fixture 150, the one or more grooves 152, the carrier 106, and / or the or more tubes 104 to retain the carrier 106 and / or tubes 104 in place and within the one or more grooves 152 and / or on the fixture. This may be important since maintaining a position of the carrier 106 and / or the one or more tubes 104 on the fixture and / or within the one or more grooves 152 may be challenging, especially if the one or more grooves 152 are in a complicated routing and / or the carrier 106 is thick, and / or the grooves 152 are shallow, and / or the tube 104 is not flexible.

[0049] A second carrier 110 may then be applied over the one or more tubes 104 and the carrier 106. A laminating process may take place where the second carrier 110 is laminated or otherwise attached to the bottom or base carrier 106 with the tube 104 sandwiched in between resulting in the structure illustrated in FIG. 4G. The thermal bond created during the laminating process may be between the two carriers 106, 110 and / or between one or both of the carriers 106, 110 and the tubes 104. In other words, the tube 104 may be thermally bonded to one or both of the carriers 106, 110, or the carriers 106, 110 can be bonded to each other and around the tube 104 without the tube being thermally bonded to either of the carriers 106, 110.

[0050] Referring now to FIGs. 5A-5C, the method 200 may include a step 202’ that is similar to the step 202 discussed above. In step 202’, one or more pre-formed tubes 104 may be placed in a fixture 150 having one or more predefined channels 152 (FIG. 5 A). Heat and / or pressure may be applied to the tube 104 to thermoform the tube 104’ to have a desired shape. (FIG. 5B).

[0051] The thermoformed tube 104’ can then be placed in one or more of the channels 152 according to FIGS. 4A, 4B. Alternatively, the thermoformed tubes 104’ can be attached to the carrier 106 by routing the thermoformed tube 104 under, into, or through the carrier, loops, holes, channels and / or retaining steps 108 (FIGs. 3, 8, 9). Additionally or alternatively, the thermoformed tube 104’ can be attached to the carrier 106 by one or more of the aforementioned steps disclosed herein.

[0052] FIG. 6A illustrates a tube 104 located on a fixture 150 or on a carrier 106. The fixture 150 comprises one or more positioning devices 158. The one or more positioning features are configured position the one or more tubes 104 in a certain configuration, pattern, or route on the fixture 150 or on the carrier 106. The one or more positioning devices 158 may be one or more pins, posts, projections, or walls that help guide the tube 104 into a predetermined or desired position on the carrier 106 or fixture 150 to prevent the tube 104 from moving out of position. In some configurations, the one or more positioning devices 158 may comprise tape, an adhesive such as hot melt glue, or other that is used to at least temporarily retain or maintain a position of the tube on the carrier or fixture. The one or more positioning devices 158 may be used in combination with the vacuum or negative air pressure discussed above the maintain a position of the tube 104 on the fixture 150 or carrier 106. Alternatively, the one or more positioning devices 158 may be used in place of or instead of vacuum or negative air pressure. The fixture 150 or carrier 106 used with the one or more positioning devices 158 may or may not include one or more channels, like the channels 152 illustrated and described above at FIGS. 4A- 4B. In other words, if the fixture 150 or carrier 106 includes channels 152, then the one or more positioning devices 158 may be arranged around the channels 152 to prevent or restrict the tube 104 from popping or moving out of the channels 152. In some configurations, like discussed above, a carrier 106 may be placed on the fixture 150 and then the tube can be routed into a desired position by placing the tube 104 within or around the one or more positioning devices 158. A top carrier 110 may be placed over tube 104 and / or the bottom carrier 106. A thermal bond can be created during a laminating process between the two carriers 106, 110 and / or between one or both of the carriers 106, 110 and the tubes 104. In other words, the tube 104 may be thermally bonded to one or both of the carriers 106, 110, or the carriers 106, 110 can be bonded to each other and around the tube 104 without the tube being thermally bonded to either of the carriers 106, 110.

[0053] FIG. 7 illustrates a head 160 for use in securing one or more tubes and / or one or more retaining devices or straps to one or more carriers. The head 160 comprises an opening 162 defined between two opposing legs 164. The opening 162 has a size and shape that is generally the same as or slightly larger than a tube 104. During use, heat and / or pressure can be applied to the head 160 for transfer to the carrier, tube, and / or retaining strap 108 as follows.

[0054] During use, a tube 104 may be provided onto the carrier 106 according to any of the embodiments or steps disclosed herein. A retaining strap 108 may be placed over the one or more tubes 104. The head 160 may be lowered down onto the strap 108 such that the legs 164 are provided around the tube 104. The head 160 may be lowered until the ends of the legs 164 contact and press the strap 108 against the carrier 106. Heat and / or pressure can be applied through the legs 164 to thermally bond the strap 108 to the carrier 106 with the tube 104 therebetween. Heat and / or pressure may optionally bond the tube 104 to the retaining strap 108 and / or carrier 106.

[0055] FIG. 9 illustrates tubes 104 secured to a carrier 106 under retaining straps 108, made or assembled according to the teachings herein.

[0056] The following description applies to all examples disclosed herein unless otherwise noted.

[0057] The assembly machine may be any machine suitable for assembling one or more tubes to a carrier, a carrier to one or more tubes, a carrier to another carrier, or any combination thereof. The assembly machine may be a press, an oven, a laminating machine, a laminating press, a thermoforming machine, a welding machine, a heat staking machine, or any combination thereof. The assembly machine may be a hot lamination or cold lamination. The assembly machine may comprise a heat gun or similar device. The assembly machine may include applying welding, RF (radio frequency) welding, holt plate welding, melting, or a combination thereof to create one or more bonds between the one or more carriers and / or the one or more tubes and one or more carriers.

[0058] The pneumatic device may include one or more carriers. The one or more carriers may be a bottom or base carrier and / or one or more top of cover carriers. A carrier may be made of a suitable material that is substantially flexible and able to conform to the cushion and surrounding structure of the vehicle seat. For example, a carrier may be made from any suitable material such as foam, cloth, nylon, polyester, cotton, linen, fabric, vinyl, leather, insulation, awoven or non-woven material; fleece, felt, spun bond material, polyester material, a PET material (polyethylene terephthalate) polyester material, a TPU material, a polyester point bond material, nylon, polymeric material, such as plastics, elastomers, thermoplastics, polyurethane, Visqueen, composites or the like, or a combination thereof. A carrier may be flexible and / or configured to conform to various supporting and / or adjacent geometries of the vehicle, vehicle seat, and / or other adjacent structure. A carrier may be configured as a base or structure on which elements of pneumatic system are supported. A carrier may be configured as a top or cover under which one or more elements of pneumatic system are supported. The carrier may be provided as a sheet, strip, or panel.

[0059] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The above description is intended to be illustrative and not restrictive. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use.

[0060] Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to this description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0061] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element or step might be divided into separate plural elements or steps.

[0062] The disclosure of "a" or "one" to describe an element or step is not intended to foreclose additional elements or steps. For example, disclosure of “a motor” does not limit the teachings to a single motor. Instead, for example, disclosure of “a motor” may include “one or more motors.”

[0063] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used todistinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings.

[0064] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0065] The invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

[0066] Any of the elements, components, regions, layers and / or sections disclosed herein are not necessarily limited to a single embodiment. Instead, any of the elements, components, regions, layers and / or sections disclosed herein may be substituted, combined, and / or modified with any of the elements, components, regions, layers and / or sections disclosed herein to form one or more embodiments that may be specifically illustrated or described herein.

[0067] The disclosures of all articles and references, including patent applications and publications, testing specifications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

Claims

CLAIMS1) A pneumatic device for an occupant support device comprising: a carrier material; one or more air cells attached to the carrier material; one or more tubes connected to the one or more air cells; wherein the one or more tubes are laminated to the carrier material.2) A method of making the pneumatic device according to claim 1, wherein the method comprises: attaching the one or more tubes to the carrier material by a laminating process.3) The method according to claim 2, wherein the method comprises: arranging the one or more tubes on a fixture; applying the carrier material over the one or more tubes in the fixture; and laminating the carrier material to the one or more tubes to attach the one or more tubes to the carrier material.4) The method according to claim 3, wherein the method comprises applying negative air pressure on the one or more tubes to retain the one or more tubes on the fixture or carrier.5) The method according to claim 3 or 4, wherein the fixture comprises one or more positioning features to position the one or more tubes in a certain configuration on the fixture or carrier.6) The method according to claim 3, 4, or 5, wherein the fixture comprises one or more channels in which the one or more tubes are positioned in; wherein the negative air pressure retains the one or more tubes in the one or more channels and / or the one or more positioning features position the one or more tubes within the one or more channels.7) The method according to claim 5 or 6, wherein the one or more positioning features are one or more pins or posts.8) The method according to any one of claims 3-7, wherein the method comprises applying a top carrier over the one or more tubes and the carrier material and then applying heat to the top carrier to attach the top carrier to the one or more tubes and / or to the carrier material.9) The method according to any one of claims 3-7, wherein the method comprises arranging the one or more tubes between two carrier materials, and then laminating the one or more tubes between the two carrier materials.10) The method according to claim 8 or 9, wherein the two carrier materials are the same.11) The method according to claim 8 or 9, wherein the two carrier materials are different (e.g., one of the two carrier materials is a fleece or felt and the other carrier material is a PU foil.12) The method according to any one of the previous claims, wherein the laminating step takes place in a laminating press.13) The method according to any one of the previous claims or to claim 1, wherein the carrier material is configured as a heater mat that comprises one or more heating elements.14) The method according to any one of the previous claims or to claim 1, wherein the carrier material is configured as a separate material or carrier from a heater mat that comprises one or more heating elements.15) A pneumatic device for an occupant support device comprising: a carrier material; one or more air cells attached to the carrier; one or more tubes connected to the one or more air cells; wherein the one or more tubes are thermoformed before attaching to the carrier material.16) A method of making the pneumatic device according to claim 15, wherein the method comprises: arranging the one or more tubes in one or more predefined channels in a fixture; exposing the one or more tubes to an elevated temperature to thermoform the one or more tubes; and attaching the thermoformed tubes to the carrier material.17) The method according to claim 16, wherein the one or more predefined channels comprise a retention device to retain the one or more tubes therein before and after the arranging and exposing steps, wherein the retention device comprises: a magnet arranged in the fixture and a magnetic device inserted into the one or more tubes; negative air pressure applied to the one or more tubes and / or fixture; and / or one or more pins or posts.18) A method of making a pneumatic device comprising a carrier material; one or more air cells and one or more tubes connected to the one or more air cells; one or more retaining devices configured to attach the one or more tubes to the carrier material; wherein the method comprises: arranging the one or more tubes on the carrier material; arranging the one or more retaining devices over the one or more tubes so that a portion of the one or more retaining devices overlaps the one or more tubes and a portion of the one or more retaining devices overlaps the carrier material; and then bonding the one or more retaining devices to the carrier material with a head.19) The method according to claim 18, wherein the head comprises one or more recessed regions to accommodate the one or more tubes and the one or more retaining devices.20) The method according to claim 19, wherein the recessed region is defined by two legs that are configured to bond the one or more retaining devices to the carrier material.

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